Warehouse Model at the Athletic Shoe Company
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Transcript of Warehouse Model at the Athletic Shoe Company
Warehouse Model at the Athletic Shoe Company
Anh Pho & Gail Savage
Simulation & Modeling Analysis (DSES 6220)
Professor: Ernesto Gutierrez-Miravete
12-21-00
Introduction
Project is based on Case #3 in Harrell– Warehouse modeling problem
Project involves 2 tasks– Designing shoe storage area– Modeling customer shipments process & stock
receiving process
Shoe Storage System
Needs to fit in physical space Needs to hold 3,000,000 pairs of shoes with
3,000 different SKUs Designed bin storage able to hold 112 prs.
Single Row Elevation View
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75
Storage Layout View (Top View)
Height=35 ft (10 Bins)
Length= 525 ft (75 Bins)
Storage Bin
Storage/RetrievalMachine
Row 1
Row 2
Row 3
Row 20
P/DStation
P/DStation
P/DStation
P/DStation
Storage System Layout
Simulation Model
Shipping Process– Entity is the customer order– Filled by a single filler
Stock Receiving Process– Entity is the receiving order– Stocking is done by a single “put away guy”
Assumptions
All SKUs are equally shipped Warehouse is fully stocked at beginning Receiving arrival rate and shipping arrival
rate are the same No down time Fillers and “put away guys” have the same
service rate Warehouse runs 24 hours/day
The Simulation Model Reduced model
Shipping Rate (pairs/day) 7,000 – 8,000
Inventory Requirement (pairs) 6000
Quantity per Shipping Order (pairs/order) 1 – 4
SKU per Order (Sku/order) 1 – 4
Receiving Rate (pairs/day) 7,000-8,000
Model elements
Locations Resources
Customer order pickup Fillers
Inspection table Packers
Packing queue Inspectors/Sorters
Packing table Put away guys
Pickup tables
Put away tables
Receiving table
Shipping queue
Stocking queue
Verification/Validation
Verification– Found syntax errors– Watch model animation– Semantic errors– Watch selective trace runs
Validation– Watch model animation behavior– Counter values– ProModel demo program
Performance Metrics
Metric Goal Simulation Results
Resource Utilization At least 80% Above 80%
Inventory Level Approx. 6,000 prs 5,738 prs.
No. prs.Shipped/Day
7,000 – 8,000 prs 7,656 prs
Resource Utilization
Conclusion
Storage area was designed Model was created, verified and validated Meets all current performance metrics Can be used to perform “what ifs” for
future demands